Shelf-stable shredded cheese

ABSTRACT

The present invention provides shelf-stable shredded cheeses and methods of preparing such shelf-stable shredded cheeses using a combination of a natural or process cheese, a cheese powder, glycerin, and a filler. The shredded cheeses of this invention are shelf-stable at ambient temperatures, have good organoleptic properties, and exhibit good melt restriction and essentially no browning upon melting. The shredded cheeses of this invention are especially adapted for incorporated into, or use on or with, snack foods (e.g., chips) for retail sale which can be stored at ambient temperatures.

FIELD OF THE INVENTION

[0001] This invention relates to shelf-stable shredded cheeses andmethods of preparing such shelf-stable shredded cheeses using acombination of natural or process cheese, cheese powder, glycerin, andfiller. The shredded cheeses of this invention are shelf-stable atambient temperatures, have good organoleptic properties (e.g., notbrittle or dry), and exhibit good melt restriction with essentially nobrowning upon melting. The shredded cheeses of this invention areespecially adapted for incorporated into, or use on or with, snack foods(e.g., chips and the like).

BACKGROUND OF THE INVENTION

[0002] Shredded cheese is a growing component of the overall cheesemarket largely because such a product offers the consumer convenience inthe preparation of a wide variety of products in the home kitchen.Shredded cheeses, for example, can be used as toppings or ingredients inhomemade dishes such as pizzas, casseroles, salads, and the like and inretail snack products.

[0003] Shredded cheeses often employ anti-caking agents such ascellulose-based products or formulations. For example, U.S. Pat. No.5,626,893 (May 6, 1997) provided an anti-caking agent formulated fromfine mesh vegetable flour, bentonite, cellulose, and antimycotic agentsor bacterial cultures. This anti-caking agent reportedly reduces thestickiness of the chunked, diced, or shredded cheese, improves thefunctionality of the cheese, and reduces yeast and/or mold growth.

[0004] U.S. Pat. No. 5,876,770 (Mar. 2, 1999) provided a reduced fatshredded cheese prepared by applying a small amount of fat to thesurface of an essentially fat-free shredded natural cheese. The reducedfat shredded cheese product had melt and mouthfeel characteristicssimilar to that of the corresponding full-fat cheese product but withsignificantly reduced levels of fat. More recently, U.S. patentapplication Ser. No. 09/618,514, filed Jul. 18, 2000 (assigned to theassignee of the present application and hereby incorporated byreference) provided natural cheese shreds containing a nutritionalcalcium supplement; the calcium supplement also providednon-agglomerating properties whereby conventional anti-caking agentscould be significantly reduced or eliminated.

[0005] Conventional cheese products generally have water activities ofabout 0.92 to about 1 and must, therefore, be stored at refrigeratedtemperatures. Attempts to produce shelf-stable cheese which can bestored at room temperature have generally involved the reduction ofmoisture in the cheese composition. Such efforts generally result in abrittle and dry cheese which is not acceptable for most uses. Suchdefects are especially noticeably when such cheeses are used to prepareshredded cheese because of the increased surface area of shreddedcheese.

[0006] Using the process of this invention, shredded cheeses which areshelf-stable at ambient temperatures and exhibit good melt restrictionand essentially no browning (i.e., when melted at about 375° F. forabout 3 minutes) can be prepared. Using a combination of a natural orprocess cheese, a cheese powder, glycerin, and a filler, the presentinvention provides a shelf-stable shredded cheese having low wateractivity without brittleness and dryness. The shredded cheeses of thisinvention are especially adapted for incorporated into, or use on orwith, retail snack foods.

SUMMARY OF THE INVENTION

[0007] The present invention provides shelf-stable shredded cheeses andmethods of preparing such shelf-stable shredded cheeses using acombination of a natural or process cheese, a cheese powder, glycerin,and a filler. The shredded cheeses of this invention are shelf-stable atambient temperatures, have good organoleptic properties, and exhibitgood melt restriction and essentially no browning upon melting. Theshredded cheeses of this invention are especially adapted forincorporation into, or use on or with, snack foods. For example, theshredded cheeses of this invention can be used on chips, crackers, andother snack foods which can be stored at room temperatures (especiallylow water activity snack foods). If desired, such foods can be eaten asis or briefly heated in, for example, a microwave oven before consuming.An especially preferred food product prepared with the shredded cheeseof this invention is a low water activity chip topped with the shreddedcheese of this invention and spices; such a product can be storedwithout refrigeration and is suitable eating as it or for heating (e.g.,sufficient to melt the cheese) by the consumer prior to consumption.

[0008] The shelf-stable shredded cheese of the present inventioncomprises (1) natural or process cheese, (2) cheese powder, (3)glycerin, and (4) filler; wherein the shelf-stable shredded cheese has awater activity of less than about 0.5, exhibits good melting properties,and has a shelf life of at least about 3 months at ambient temperatures.A preferred shelf-stable shredded cheese comprises (1) about 3 to about30 percent natural or process cheese, (2) about 5 to about 60 percentcheese powder, (3) about 5 to about 25 percent glycerin, (4) about 15 toabout 45 percent filler, (5) 0 to about 25 percent sweetness modifier,and (6) 0 to about 5 percent emulsifier; wherein the shelf-stableshredded cheese has a water activity of less than about 0.5, exhibitsgood melting properties, and has a shelf life of at least about 3 monthsat ambient temperatures. A more preferred shelf-stable shredded cheesecomprises (1) about 10 to about 20 percent natural or process cheese,(2) about 30 to about 45 percent cheese powder, (3) about 5 to about 15percent glycerin, (4) about 20 to about 40 percent filler, (5) 0 toabout 3 percent sweetness modifier, and (6) 0 to about 3 percentemulsifier; wherein the shelf-stable shredded cheese has a wateractivity of about 0.3 to about 0.45, exhibits good melting properties,and has a shelf life of at least about 3 months at ambient temperatures.When included in the compositions of this invention, the sweetnessmodifier is preferably at about 0.5 to about 3 percent and theemulsifier is preferably at about 0.5 to about 3 percent.

[0009] In another embodiment, the present invention provides ashelf-stable shredded cheese comprising (1) a cheese product selectedfrom the group consisting of natural cheese, process cheese, cheesepowder, and mixtures thereof, (2) glycerin, and (4) filler; wherein theshelf-stable shredded cheese has a water activity of less than about0.5, exhibits good melting properties, and has a shelf life of at leastabout 3 months at ambient temperatures. A more preferred shelf-stableshredded cheese comprises (1) about 3 to about 60 percent cheeseproduct, (2) about 5 to about 15 percent glycerin, (3) about 20 to about40 percent filler, (4) 0 to about 3 percent sweetness modifier, and (5)0 to about 3 percent emulsifier; wherein the shelf-stable shreddedcheese has a water activity of about 0.3 to about 0.45, exhibits goodmelting properties, and has a shelf life of at least about 3 months atambient temperatures. Preferably, the chesses product contains bothnatural or process cheese and cheese powder.

[0010] The present invention also provides a method of preparing ashelf-stable shredded cheese, said method comprising (A) heating amixture comprising (1) about 3 to about 30 percent natural or processcheese, (2) about 5 to about 60 percent cheese powder, (3) about 5 toabout 25 percent glycerin, (4) about 15 to about 45 percent filler, (5)0 to about 25 percent sweetness modifier, and (6) 0 to about 5 percentemulsifier at a temperature and for a time sufficient to obtain ahomogenous mixture; (B) cooling the homogenous mixture to form a solidcheese composition; and (C) shredding the solid cheese composition toform the shelf-stable shredded cheese, wherein the shelf-stable shreddedcheese has a water activity of less than about 0.5, exhibits goodmelting properties, and has a shelf life of at least about 3 months atambient temperatures. Water can be added as need; unless the level ofnatural or process cheese is low, no additional water, other than thatcontained in the various components, is generally required.

DETAILED DESCRIPTION OF THE INVENTION

[0011] The present invention provides a shelf-stable shredded cheesewhich has a water activity of less than about 0.5, exhibits good meltingproperties, and has a shelf life of at least about 3 months at ambienttemperatures. More preferably, the shelf-stable shredded cheese of thepresent invention has a water activity of about 0.3 to about 0.45 and ashelf life of at least about 3 months at ambient temperatures. Forpurposes of this invention, “good melting properties” is intended tomean that the shredded cheese exhibits good melt restriction (i.e.,significant reduction or elimination of both stickiness and rapid skinformation upon melting), exhibits essentially no browning and generallyretains its shape or form upon melting (i.e., heated to about 375° F.for three minutes).

[0012] The shelf-stable shredded cheese of the present inventioncomprises (1) natural or process cheese, (2) cheese powder, (3)glycerin, and (4) filler; wherein the shelf-stable shredded cheese has awater activity of about 0.3 to about 0.45, exhibits good meltingproperties, and has a shelf life of at least about 3 months at ambienttemperatures. A preferred shelf-stable shredded cheese comprises (1)about 3 to about 30 percent natural or process cheese, (2) about 5 toabout 60 percent cheese powder, (3) about 5 to about 25 percentglycerin, (4) about 15 to about 45 percent filler, (5) 0 to about 25percent sweetness modifier, and (6) 0 to about 5 percent emulsifier. Amore preferred shelf-stable shredded cheese comprises (1) about 10 toabout 20 percent natural or process cheese, (2) about 30 to about 45percent cheese powder, (3) about 5 to about 15 percent glycerin, (4)about 20 to about 40 percent filler, (5) 0 to about 3 percent sweetnessmodifier, and (6) 0 to about 3 percent emulsifier.

[0013] The process or natural cheeses employed in the present inventionmay be derived from the treatment of any dairy liquid that providescheese curds upon renneting (using either cheese-making cultures ordirect acidification). Suitable natural cheeses include, by way ofnonlimiting example, Cheddar cheese, Colby cheese, Monterey Jack,Havarti cheese, Muenster cheese, Brick cheese, Gouda cheese, and thelike. For purposes of this invention, “process or natural cheeses” isintended to include cream cheeses and other soft cheeses. Mixtures ofsuch natural cheeses and process cheeses may also be used. Generally theprocess or natural cheese is present in the present compositions atabout 3 to about 30 percent, and more preferably about 10 to about 20percent.

[0014] Suitable cheese powders include commercially available cheesepowders prepared from natural or process cheeses. Such cheese powdersgenerally have a low moisture content (generally less than about 3percent). Examples of suitable commercially available cheese powdersincluded, for example, Cheez Tang®, Sequio®, and Exceed® 2000 (availablefrom Kraft Foods, Inc.). Generally the cheese powder is present in thepresent compositions at about 5 to about 60 percent, and more preferablyat about 30 to about 45 percent.

[0015] The shelf-stable shredded cheese of the present invention containsignificant amounts of glycerin (generally about 5 to about 30 percent).Although not wishing to be limited by theory, the glycerin appears toact as a solvent to help overcome the brittleness and dryness normallyassociated with low moisture cheese products. By incorporating glycerinin the present compositions, organoleptic pleasing cheese shreds can beobtained at low moisture levels (i.e., water activities below about0.5). Glycerin also appears to provide the composition with sweetnesslevel that may be undesirable. If desired, corn syrup (generally at 0 toabout 10 percent) can be included in the composition to replace aportion of the glycerin or to supplement the glycerin.

[0016] The present compositions also contain fillers (generally at about5 to 45 percent, preferably at about 20 to about 40 percent) to providebody and texture to the compositions. Suitable fillers include, forexample, starches, fibers, inulin, dextrose, gums (i.e., water binders),and the like. Preferred fillers include the fat replacement compositionsdescribed in U.S. Pat. Nos. 6,658,609 (Aug. 19, 1997; vegetable fiber,starch, and gum) and 5,851,576 (Dec. 22, 1998; inulin and emulsifiers).

[0017] The shelf-stable shredded cheese of the present invention mayalso contain other ingredients so long as they do not significantly andadversely effect the organoleptic, melting, or stability properties ofthe present compositions. Such optional ingredients include, forexample, sweetness modifiers (e.g., acid whey, sweet whey, whey proteinconcentrate, sugar inhibitors, and the like), emulsifiers (e.g.,disodium phosphate, dipotassium phosphate, tricalcium phosphate, and thelike), gums (e.g., carboxymethyl cellulose, xanthan, guar, and thelike), flavorants (e.g., salt, cheese flavors, and the like), colorants,nutritional supplements (e.g., vitamins, minerals, antioxidants,probiotics, botanicals, and the like), anti-caking agents (e.g., calciumsulfate, potassium starch, cellulose, and the like), and the like aswell as mixtures thereof. Although the shredded cheeses of thisinvention are shelf stable for long periods at ambient temperatureswithout any added preservatives, preservatives (e.g., natamycin, nisin,and the like), can be added if desired; it is generally preferred,however, that preservatives are not added.

[0018] Preferably, one or more of these optional ingredients areincluded in the present compositions. Sweetness modifiers are generallyincluded in the present composition at 0 to about 25 percent, morepreferably at about 3 to about 10 percent. Emulsifiers are generallyincluded in the present composition at 0 to about 5 percent, morepreferably at about 1 to about 3 percent. Gums are generally included inthe present composition at 0 to about 3 percent, more preferably at 0 toabout 0.2 percent. Flavorants are generally included in the presentcomposition at 0 to about 2 percent, more preferably at about 0.1 toabout 0.5 percent. Colorants are generally included in the presentcomposition at 0 to about 1 percent, more preferably at about 01 toabout 0.5 percent. If desired, nutritional supplements (generally atlevels of 0 to about 2 percent) can be included in the presentcomposition. If desired, preservatives (generally at levels of 0 toabout 2 percent) can be included in the present composition. Anti-cakingagents are generally included in the present composition at 0 to about 5percent, more preferably at about 1 to about 3 percent.

[0019] The shelf-stable shredded cheese of the present invention aregenerally prepared by mixing the natural or process cheese and glycerin(as well as any other liquid ingredients such as, for example, cornsyrup) for a time and at a temperature sufficient to provide ahomogenous mixture. Generally the natural or process cheese and glycerinare heated to about 110 to about 160° F. for about 5 to about 15minutes. Although the other ingredients can be added at any time, it isgenerally preferred that the dry ingredients be added after theformation of the homogenous mixture of natural or process cheese andglycerin. Once the dry ingredients are added, mixing is continued untila homogenous cheese product is obtained; generally this mixing is at atemperature of about 100 to about 130° F. for about 5 to about 15minutes. Once the final homogenous cheese mixture has been obtained, itis cooled to about 20 to about 45° F. After cooling, the finalhomogenous cheese mixture can be shredded immediately or at a later timeto form pieces whose sizes are suitable for shredded cheese. In general,cheese fragments used in the present invention may be regular orirregular sized shreds, particles, or slices; regular sized shreds orparticles are preferred. The size of the shredded pieces can vary widelybut are generally about {fraction (1/32)} to about ⅜ inches in diameterand about 0.75 to about 3 inches in length; more preferably, they areabout {fraction (1/16)} to about ⅛ inches in diameter and about 1 toabout 2 inches in length. Of course, other shaped particles havingsimilar dimensions to those just discussed can be used in the practiceof this invention; such other shaped particles are intended to beincluded within the terms “shreds,” “shredded,” and the like.

[0020] The following examples are intended to illustrate the inventionand not to limit it. Unless noted otherwise, all percentages throughoutthis specification are by weight. All patents, patent applications, andpublication cited herein are incorporated by reference.

EXAMPLE 1

[0021] The following cheese formulations were prepared: Sample 1 Sample2 (%) (%) Sample 3 (%) Sample 4 (%) Cheese 16.2 16.2 16.2 16.2 CheesePowder 41.7 41.6 41.8 41.6 Glycerin 14.6 14.6 14.4 16.2 Gellan Gum 1.61.6 0 0 Salt 1.6 1.6 1.6 1.6 Instant Starch 6.8 6.8 6.9 6.8 Filler I*15.6 15.5 0 0 Filler II** 0 0 17.2 15.3 Cheese Flavor 0 0.1 0 0.1Colorant 0 0.8 0 0.05 Disodium 1.9 1.9 1.9 1.9 Phosphate

[0022] In a steam jacketed bowl, the cheese, cheese powder, and glycerinwere heated to about 100° F., for about 15 minutes to obtain ahomogenous mixture. The emulsifier, filler I or II, and gum were addedwith continuous mixing after which the remaining ingredients were added.Mixing was continued for about 20 minutes at about 130° F. until ahomogenous mixture was obtained. After cooling to about 40° F., ashredded cheese was formed using a conventional shredder; generally thesheds were, on average, about {fraction (1/16)} inches in diameter andabout 1 inch in length. The following results were obtained. WaterSample Activity Comments 1 0.416 Shredded well; no browning upon melting2 0.460 Shredded well; slight browning on edges of shreds upon melting 30.405 Shreds torn on edges; no browning upon melting 4 0.410 Shreds tornon edges; browning on ends of shreds upon melting

[0023] All samples were shelf stable at ambient temperatures with goodorganoleptic properties.

EXAMPLE 2

[0024] The following cheese formulations were prepared: Sample 1 Sample2 (%) (%) Sample 3 (%) Sample 4 (%) Cheese 15.6 15.1 15.2 11.8 CheesePowder 42.9 43.0 41.4 32.2 Glycerin 15.0 15.1 14.5 11.3 Salt 1.7 1.7 1.61.2 Instant Starch 7.0 0 0 0 Filler* 16.0 16.0 15.4 12.0 Gum 0 0.2 0 0Disodium 1.9 1.9 1.4 1.9 Phosphate Whey 0 7.0 10.0 30.0

[0025] Heated glycerin (temperature of about 130° F. and an amount ofabout 15 percent of the total) and cheese were heated to about 150 toabout 160° F. in a mixer to form a homogenous mixture. The various dryingredients were then added and mixed into the cheese/glycerin mixturefor about 3 minutes during which time the temperature fell to about 100°F. The remainder of the glycerin (chilled to below room temperature) wasthen added with mixing and cooled to about 70 to about 75° F. Afterfurther cooling to below room temperature, the resulting cheese wasformed into cubes and then shredded using a conventional shredder;generally the sheds were, on average, about {fraction (1/16)} inches indiameter and about 1 inch in length. After shredding, an anti-cakingagent was added at about 3.5 percent and the cheese packaged under aninert gas flush. The following results were obtained. Water SampleActivity Comments 1 0.439 Good cohesive product; little sweetaftertaste; good melting properties with no browning upon melting 20.427 Good cohesive product; very good taste; good melting propertieswith no browning upon melting 3 0.405 Good cohesive product; good taste;good melting properties with no browning upon melting 4 0.406 Sourtaste; good melting properties with little browning upon melting

[0026] All samples had good melting properties (i.e., retained shapeupon heating in oven for 3 minutes at 375° F.).

EXAMPLE 3

[0027] The following formulations were prepared: Sample 1 (%) Sample 2(%) Cheese 12.8 12.8 Cheese Powder 26.2 26.1 Glycerin 11.1 11.1 CornSyrup (43DE) 3.3 3.3 Salt 1.0 1.0 Starch 3.6 3.6 Filler* 16.4 16.3 AcidWhey 19.1 19.1 Dextrose 6.5 6.5 Cheese Flavor 0 0.1

[0028] In a steam jacketed bowl, the cheese and corn syrup were heatedto about 130° F. for about 1.5 minutes to obtain a homogenous mixture.Glycerin was then added followed by the remaining ingredients. Mixingwas continued for about 3 minutes at about 130° F. until a homogenousmixture was obtained. After cooling to about 40° F., a shredded cheesewas formed using a conventional shredder; generally the sheds were, onaverage, about {fraction (1/16)} inches in diameter and about 1 inch inlength. The following results were obtained. Water Sample ActivityComments 1 0.410 Soft & cohesive with no oil out; acid whey helped masksweetness; no browning issues 2 0.400 Soft & cohesive with no oil out;better cheese flavor than Sample 1; acid whey helped mask sweetness; nobrowning issues

We claim:
 1. A shelf-stable shredded cheese comprising (1) natural orprocess cheese, (2) cheese powder, (3) glycerin, and (4) filler; whereinthe shelf-stable shredded cheese has a water activity of less than about0.5, exhibits good melting properties, and has a shelf life of at leastabout 3 months at ambient temperatures.
 2. The shelf-stable shreddedcheese of claim 1, wherein the shelf-stable shredded cheese comprises(1) about 3 to about 30 percent natural or process cheese, (2) about 5to about 60 percent cheese powder, (3) about 5 to about 25 percentglycerin, (4) about 15 to about 45 percent filler, (5) 0 to about 25percent sweetness modifier, and (6) 0 to about 5 percent emulsifier;wherein the shelf-stable shredded cheese has a water activity of about0.3 to about 0.45.
 3. The shelf-stable shredded cheese of claim 1,wherein the shelf-stable shredded cheese comprises (1) about 10 to about20 percent natural or process cheese, (2) about 30 to about 45 percentcheese powder, (3) about 5 to about 15 percent glycerin, (4) about 20 toabout 40 percent filler, (5) 0 to about 3 percent sweetness modifier,and (6) 0 to about 3 percent emulsifier.
 4. The shelf-stable shreddedcheese of claim 1, wherein the filler is selected from the groupconsisting of starch, fiber, inulin, dextrose, gum, and mixturesthereof.
 5. The shelf-stable shredded cheese of claim 2, wherein thefiller is selected from the group consisting of starch, fiber, inulin,dextrose, gum, and mixtures thereof.
 6. The shelf-stable shredded cheeseof claim 3, wherein the filler is selected from the group consisting ofstarch, fiber, inulin, dextrose, gum, and mixtures thereof.
 7. Theshelf-stable shredded cheese of claim 5, wherein the sweetness modifieris selected from the group consisting of acid whey, sweet whey, wheyprotein concentrate, sugar inhibitors, and mixtures thereof.
 8. Theshelf-stable shredded cheese of claim 6, wherein the sweetness modifieris selected from the group consisting of acid whey, sweet whey, wheyprotein concentrate, sugar inhibitors, and mixtures thereof.
 9. A methodof preparing a shelf-stable shredded cheese, said method comprising (A)heating a mixture comprising (1) about 3 to about 30 percent natural orprocess cheese, (2) about 5 to about 60 percent cheese powder, (3) about5 to about 25 percent glycerin, (4) about 15 to about 45 percent filler,(5) 0 to about 25 percent sweetness modifier, and (6) 0 to about 5percent emulsifier at a temperature and for a time sufficient to obtaina homogenous mixture; (B) cooling the homogenous mixture to form a solidcheese composition; and (C) shredding the solid cheese composition toform the shelf-stable shredded cheese, wherein the shelf-stable shreddedcheese has a water activity of less than about 0.5, exhibits goodmelting properties, and has a shelf life of at least about 3 months atambient temperatures.
 10. The method of claim 9, wherein the mixture inStep (A) comprises (1) about 10 to about 20 percent natural or processcheese, (2) about 30 to about 45 percent cheese powder, (3) about 5 toabout 15 percent glycerin, (4) about 20 to about 40 percent filler, (5)0 to about 3 percent sweetness modifier, and (6) 0 to about 3 percentemulsifier.
 11. The method of claim 9, wherein the filler is selectedfrom the group consisting of starch, fiber, inulin, dextrose, gum, andmixtures thereof.
 12. The method of claim 10, wherein the filler isselected from the group consisting of starch, fiber, inulin, dextrose,gum, and mixtures thereof.
 13. The method of claim 9, wherein thesweetness modifier is selected from the group consisting of acid whey,sweet whey, whey protein concentrate, sugar inhibitors, and mixturesthereof.
 14. The method of claim 10, wherein the sweetness modifier isselected from the group consisting of acid whey, sweet whey, wheyprotein concentrate, sugar inhibitors, and mixtures thereof.
 15. Themethod of claim 11, wherein the sweetness modifier is selected from thegroup consisting of acid whey, sweet whey, whey protein concentrate,sugar inhibitors, and mixtures thereof.
 16. The method of claim 12,wherein the sweetness modifier is selected from the group consisting ofacid whey, sweet whey, whey protein concentrate, sugar inhibitors, andmixtures thereof.
 17. A shelf-stable shredded cheese comprising (1) acheese product selected from the group consisting of natural cheese,process cheese, cheese powder, and mixtures thereof, (2) glycerin, and(4) filler; wherein the shelf-stable shredded cheese has a wateractivity of less than about 0.5, exhibits good melting properties, andhas a shelf life of at least about 3 months at ambient temperatures. 18.The shelf-stable shredded cheese of claim 1, wherein the shelf-stableshredded cheese comprises (1) about 3 to about 60 percent cheeseproduct, (2) about 5 to about 15 percent glycerin, (3) about 20 to about40 percent filler, (4) 0 to about 3 percent sweetness modifier, and (5)0 to about 3 percent emulsifier; wherein the shelf-stable shreddedcheese has a water activity of about 0.3 to about 0.45, exhibits goodmelting properties, and has a shelf life of at least about 3 months atambient temperatures.